GM Testing New Magnesium Forming Process, Could Be Used on 2014 Silverado

The race to meet new CAFE standards is on, and one area automakers are exploring to gain an edge is weight reduction. General Motors is testing a thermal-forming process and proprietary treatment to help prevent corrosion of lightweight magnesium, a high-strength future alternative to aluminum and steel. We previously reported GM may employ magnesium and other alloys to keep weight down (and fuel economy up) in the next-gen Silverado. Could this new process be used to form body panels for Chevy’s upcoming pickup?

GM wants to increase its use of lightweight parts on its vehicles globally, which is why it’s hard at work developing and pursuing licensing opportunities for lightweight technology. GM’s goal is to sufficiently develop the forming process so that it can provide enough magnesium to shave pounds off curb weights. Whether the cost of the technology will affect vehicle prices is unclear.GM has already used this process to produce a magnesium deck lid inner panel, which held up after 77,000 robotic slams and 550-pound impacts. The automaker says this piece is production-ready, and is 2.2 pounds lighter than a steel panel thanks to magnesium’s inherently lightweight properties, which make it weigh 33 percent less than aluminum, 60 percent less than titanium, and 75 percent less than steel.

Although other automakers have attempted to produce strong, corrosion-resistant magnesium sheet panels through traditional forming techniques, GM says that its. process heats magnesium to 842 degrees Fahrenheit, which allows the metal to be molded more precisely. Though die-cast magnesium has been used before for parts like steering wheels and engine cradles, GM claims it’s the first to use thermal-formed magnesium in structural applications.As we said previously, the 2014 Silverado will likely get a next-gen small-block V-8 with direct-injection technology. The full-size pickup is also expected to shed precious dead weight through use of lightweight materials like magnesium and aluminum, materials we may see more of on the next-gen Ford F-150 as well. If structural pieces of magnesium are now possible, it might make sense for GM to consider using the technology to boost the fuel economy of one of its least efficient offerings, especially with versions of the new 2013 Ram 1500 EPA-rated as high as 24 and 25 mpg on the highway.

I would think this would be more expensive to produce especially at first. How much more initial expense are consumers going to be to willing to pay upfront for better fuel efficiency? Not to mention higher selling price means more sales tax and more interest paid. I'm sure there is going to be a tipping point of when it is not worth it. Fuel prices and CAFE will dictate!